Direct Metal Laser Sintering (DMLS) is one of the leading additive manufacturing processes, which produces complex metallic parts directly from the powder. One of the major problems of this rapid manufacturing process is an inhomogeneous temperature distribution, which leads to residual stress in the build part. Thus, temperature analyses must be performed, to better understand the temperature distribution and sintering behavior of the powder bed with a different laser recipe. In this study, a comprehensive three-dimensional numerical model was developed to understand the temperature distribution during direct metal laser sintering of AlSi10Mg alloy powder. The computer simulation was carried out in ANSYS 17.0 platform. Further, the effect of process parameters such as laser power and scan speed on the temperature distribution and sintering behavior were studied. From the simulation results, it was found that, when the laser power increased from 70 W to 190 W, the maximum temperature of the molten pool increased from 731 °C to 2672 °C, and the molten pool length changed from 0.286 mm to 2.167 mm. A reverse phenomenon was observed with an increase in scan speed. The sintering depth of the powder layer increases significantly from 0.061 mm to 0.872 mm with increasing the applied laser power, but decreased from 0.973 mm to 0.209 mm as a higher scan speed was applied. The developed model helps to optimize the powder layer thickness and minimize the wastage of excess powders during the sintering process.
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Mihir Samantaray 1 ; Seshadev Sahoo 1 ; Direndranath Thatoi 1
@article{CRMECA_2018__346_11_1043_0, author = {Mihir Samantaray and Seshadev Sahoo and Direndranath Thatoi}, title = {Computational modeling of heat transfer and sintering behavior during direct metal laser sintering of {AlSi10Mg} alloy powder}, journal = {Comptes Rendus. M\'ecanique}, pages = {1043--1054}, publisher = {Elsevier}, volume = {346}, number = {11}, year = {2018}, doi = {10.1016/j.crme.2018.08.006}, language = {en}, }
TY - JOUR AU - Mihir Samantaray AU - Seshadev Sahoo AU - Direndranath Thatoi TI - Computational modeling of heat transfer and sintering behavior during direct metal laser sintering of AlSi10Mg alloy powder JO - Comptes Rendus. Mécanique PY - 2018 SP - 1043 EP - 1054 VL - 346 IS - 11 PB - Elsevier DO - 10.1016/j.crme.2018.08.006 LA - en ID - CRMECA_2018__346_11_1043_0 ER -
%0 Journal Article %A Mihir Samantaray %A Seshadev Sahoo %A Direndranath Thatoi %T Computational modeling of heat transfer and sintering behavior during direct metal laser sintering of AlSi10Mg alloy powder %J Comptes Rendus. Mécanique %D 2018 %P 1043-1054 %V 346 %N 11 %I Elsevier %R 10.1016/j.crme.2018.08.006 %G en %F CRMECA_2018__346_11_1043_0
Mihir Samantaray; Seshadev Sahoo; Direndranath Thatoi. Computational modeling of heat transfer and sintering behavior during direct metal laser sintering of AlSi10Mg alloy powder. Comptes Rendus. Mécanique, Volume 346 (2018) no. 11, pp. 1043-1054. doi : 10.1016/j.crme.2018.08.006. https://comptes-rendus.academie-sciences.fr/mecanique/articles/10.1016/j.crme.2018.08.006/
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